Service Procedure
Brake Master Cylinder Inspection
1. Remove the air intake tube/boot between the air cleaner assembly and intake manifold (see Figure 1).
a. Loosen the 2 band clamps.
b. Remove the clip that holds the vent tube.
c. Release the spring clamp.
d. Remove the intake tube/boot.
2. Carefully pull the vacuum tube from the brake booster (see Figure 2).
3. Remove the rubber grommet from the brake booster (see Figure 2).
4. Cover fenders and painted areas to protect them from possible brake fluid splashing.
CAUTION:
If brake fluid is splashed on painted surfaces, immediately wipe off with a clean soft cloth and wash with water.
IMPORTANT
5. Connect Special Tool J-49749 as shown in Figure 3.
^ Use shop air supply pressure between 90 and 120 psi.
6. Move/position the suction tube inside the brake booster so that any fluid in the lower area of the brake booster is sucked into the collection container.
NOTE:
If there is fluid in the lower area of the booster:
^ Keep the collection container upright.
^ If the collection container fills to within 1/2 inch of the top, empty it and then continue.
^ Continue suction until all of the fluid is removed.
7. After you have removed any / all fluid from the brake booster, disconnect the tool and check the collection container.
No fluid in the container - OK
^ Reinstall all parts removed.
^ Make sure the brake fluid reservoir is full.
^ Return the vehicle to the customer.
Any amount of fluid in the container - NG
^ Go to "Replace the Brake Master Cylinder" below.
IMPORTANT
Brake Master Cylinder Replacement
1. Write down the radio station presets.
2. Remove the battery from the vehicle.
a. Disconnect the battery cables (negative cable first).
b. Remove the battery hold down.
c. Lift the battery from the vehicle.
3. Remove the 2 clips from the intake inlet duct and then remove the duct.
4. Remove 2 bolts shown in Figure 7 and move the main harness forward.
5. Remove the battery tray.
NOTE:
The battery tray is part of the intake duct and is attached at the front and rear.
6. Remove 2 bolts from the ECU support bracket.
7. Disconnect the brake fluid level sensor connector.
8. Disconnect the air flow meter and the harness clip.
9. Hold the ECU forward and carefully remove the air cleaner assembly.
NOTE:
Don't lose the rubber mount bushings for the air cleaner assembly.
10. Drain the fluid from the brake master reservoir as follows:
a. Make sure the parking brake is set.
b. Attach a vinyl tube with catch container to a caliper bleed valve.
d. Open the bleed valve.
e. Slowly pump the brake pedal until the brake fluid reservoir is empty.
CAUTION:
^ If equipped with manual transmission, do not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.
^ If brake fluid is splashed on painted surfaces, immediately wipe off with a soft cloth and wash with water.
11. If equipped with manual transmission remove the fluid supply tube for the clutch master cylinder.
CAUTION:
Do Not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.
12. Disconnect the 2 brake lines.
13. Remove the 2 nuts for the brake master cylinder and remove the master cylinder.
14. Prepare for installation of the new master cylinder:
^ Clean the brake booster in and around the hole for the master cylinder.
^ Make sure the brake master cylinder to booster seal is in place and fully seated as shown in Figure 16.
^ Make sure the primary piston and seal are clean and free of any debris.
CAUTION:
^ Do Not scratch the master cylinder primary piston.
^ Do Not allow the primary piston to contact the brake booster during installation.
15. Install the brake master cylinder and tighten the nuts.
^ Nut Torque:
19.6 N.m (2.0 kg-m, 14 ft-lb)
16. Attach the brake lines.
^ Brake line flare nut torque:
17 N.m (1.7 kg-m, 12 ft-lb)
17. If equipped with manual transmission, install the fluid supply tube for the clutch master cylinder.
CAUTION:
Do Not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.
18. Hold the ECU forward and carefully install the air cleaner assembly.
NOTE:
Make sure all of the rubber mount bushings are in place.
19. Connect the brake fluid level sensor.
20. Connect the air flow meter and the harness clip.
21. Install 2 bolts for the ECU support bracket.
22. Install the battery tray.
NOTE:
The battery tray is part of the intake duct and must be attached at the front and rear.
23. Install the 2 bolts shown in Figure 24.
24. Install the intake inlet duct and the 2 securing clips.
25. Install the vacuum tube rubber grommet into the brake booster (see Figure 26).
26. Carefully install / push the vacuum tube into the brake booster (see Figure 26).
27. Install the air intake tube/boot between the air cleaner assembly and intake manifold (see Figure 27).
a. Tighten the 2 band clamps.
b. Install the clip that holds the vent tube.
c. Position the spring clamp correctly.
28. Install the battery and the battery hold down bracket.
29. Attach the battery cables (positive cable first).
30. Reset the clock and the radio presets.
31. Perform the following initialization / learning items:
^ Accelerator Pedal Released Position Learning
^ Throttle Valve Closed Position Learning
^ Idle Air Volume Learning
^ Sunroof Memory Initialization - if equipped
^ Power Window System Initialization
If needed, refer to the Service Manual for information on the above items.
32. Bleed air from the brake system as follows:
NOTE:
^ Keep brake fluid reservoir filled at least half full while performing the brake bleeding procedure.
^ Use a new fresh sealed bottle of genuine Nissan Super Heavy Duty Brake Fluid (P/N 999MP-A4100P).
a. Attach a vinyl tube with catch container to the right rear brake caliper or wheel cylinder bleed valve.
b. Fully depress brake pedal 4 to 5 times.
c. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately. Figure 28
d. Repeat steps b and c until no more air comes out.
e. Tighten bleed valve. Torque to 7.8 N.m (0.8 kg-m, 69 in-lb).
f. Repeat steps a to e for the other wheels in the following order: Left Front > Left Rear > Right Front
33. If equipped with manual transmission, make sure the clutch is operating correctly by pumping/cycling the clutch pedal 3 or 4 times.